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Installation Manual NEW STYLUS TM Split System, 1-5 Tons Convertible Type MCX Series 50/60 Hz 50 Hz Models Cooling Only MCX 512 GB MCX 518 GB MCX 524 GB MCX 530 GB MCX 536 GB MCX 042 GB MCX 048 GB MCX 060 GB 60 Hz Models Cooling Only MCX 512 G1 MCX 518 G1 MCX 524 G1 MCX 530 G1 MCX 536 G1 MCX 042 G1 MCX 048 G1 MCX 060 G1 July 2007 MS-SVN015-EN.p65 1 Black MS-SVN015-EN 6/27/07, 11:23 AM General Information General Information About the Unit Caution This Installation Manual is given as a guide to good practice in the installation by the installer of MCX mini-split system. Installation procedures should be performed in the sequence that they appear in this manual. These MCX units are assembled, pressure tested, dehydrated, charged and run tested before shipment. The information contained in this manual applies to MCX units are designed to operate in cooling mode only and in cooling or heating modes. Cautions are provided at appropriate places in this manual to indicate to installers, operators, and service personnel of potentially hazardous situations which, if not avoided, MAY result in minor or moderate injury or malfunction of the unit. For installing the unit to operate properly and reliably, it must be installed in accordance with these instructions. Also, the services of a qualified service technician should be employed, through the maintenance contract with a reputable service company. Read these Installation Instructions completely before installing the air conditioning system. Trane MCX series of mini-split systems offer three styles of installation: floor, low wall and under ceiling with both LCD wireless remote control or wired control. Trane MCX series provide flexibility and savings. Note: For model MCX 042, MCX 048 and MCX 060, there are only two styles of installation: under ceiling and low wall. About this Manual Reception Cautions appear at appropriate places in this Instruction Manual. Your personal safety and the proper operation of this machine require that you follow them carefully. The Trane Company assumes no liability for installations or servicing performed by unqualified personnel. All phases of the installation of this air conditioning system must conform to all national, provincial, state and local codes. On arrival, inspect the unit before signing the delivery note. Specify any damage of the unit on the delivery note, and send a registered letter of protest to the last carrier of the goods within 72 hours of delivery. Notify the dealer at the same time. The unit should be totally inspected within 7 days of delivery. If any concealed damage is discovered, send a registered letter of protest to the carrier within 7 days of delivery and notify the dealer. Warning Warnings are provided at appropriate places in this manual to indicate to installers, operators and service personnel of potentially hazardous situations which, if not avoided, COULD result in death or serious injury. © American Standard Inc. 2005 MS-SVN015-EN.p65 Warranty is based on the general terms and conditions by country. The warranty is void if the equipment is modified or repaired without the written approval of The Trane Company, if the operating limits are exceeded or if the control system or the electrical wiring is modified. Damage due to inappropriate installation, lack of knowledge or failure to comply with the manufacturer’s instructions, is not covered by the warranty obligation. If the installation does not conform to the rules described in Installation Manual, it may entail cancellation of warranty and liabilities by The Trane Company. Important This document is customer property and is to remain with unit. Please place in service information pack upon completion of work. These instructions do not cover all variations in systems, nor do they provide for every possible contingency to be met in connection with installation. Should further information be desired or should particular problems arise which are not covered sufficiently in this manual, the matter should be referred to your authorized Trane dealer. MS-SVN015-EN 2 Black Warranty 6/27/07, 11:23 AM Contents General Information Typical Installation Location and Preparation of Units Unit Installation Connection of Refrigerant Tubing Condensate Drain Piping Electrical Installation Remote Control Installation Typical Wiring Diagram Dimensional Data Notes MS-SVN015-EN 2 4 5 6 7 9 10 11 12 16 18 3 MS-SVN015-EN.p65 3 Black 6/27/07, 11:59 AM Typical Installation Return air grille contains air filter Supply air grille Adjustable louvers direct air Ceiling mounted Indoor unit Refrigerant tubing/wiring Supply air grille Adjustable louvers direct air Outdoor unit Drain Return air grille contains air filter Low wall mounted Floor mounted Note: For models MCX 042, MCX 048, MCX 060 there are only two styles of installation: under ceiling and low wall 4 MS-SVN015-EN MS-SVN015-EN.p65 4 Black 6/27/07, 11:23 AM Location and Preparation of Units 1. Select an appropriate position that allows every corners of the room to be uniformly air conditioned and where it is easy to route the refrigerant tubing. 2. Ensure that the floor or ceiling construction is sufficient to fully support the weight of the indoor unit. 3. Consideration must be given to assure an unobstructed flow of supply and return air. 4. Refrigerant tubes between indoor and outdoor units should be as short as possible. 5. Length of the condensate drain hose should be kept as short as possible (Figure 1). 6. Recommended service clearance as shown in figure 2, 3 and 4. Min. 120 cm. . Min . m 30 c Min. 20 cm. Mi 20 n. cm . Min. m. 20 c Maintenance area (Celling mounted) Mi 30 n. cm . Figure 2 a are ) ce ted nan moun e t in ll Ma wa w (Lo Min. 20 cm. Figure 4 7. Do not install unit in direct sunlight or near other heat sources as this may affect performance. Do not allow outside air to directly enter unit or condensate may form at the unit’s discharge. . Min . m 30 c Min. m. 20 c Figure 1 a are ce d) nan ounte e t in Ma loor m (F Note: For MCX042-MCX060 the unit should be installed over the floor at least 20 cm. Figure 3 MS-SVN015-EN 5 MS-SVN015-EN.p65 5 Black 6/27/07, 11:23 AM Unit Installation 6. Unscrew at the return grille (Figure 7). Indoor Unit A 1. Select a location to route tubing, wiring and drain pipe between the indoor and outdoor units. 2. Make a hole in the wall using a key hole saw or hole-cutting drill attachment. The hole should be made at a slight downward slant to the outdoor side (Figure 5). 8.5"(215) 0.83"(21) B 0.83"(21) Outdoor side Figure 10 Figure 7 7. Unscrew at the grille bottom hinges, pull out the screw, and unscrew at the side panel front (Figure 8). Then, push down on the side panel front and pull up (Figure 9). Indoor side Figure 5 Before cutting, check that no pipes or studs are directly behind the place to be cut. Avoid areas where electrical wiring or conduits are located. 3. Place the unit on a solid and level foundation. 4. Tubing, wiring through and drain pipe of low wall and floor mounted units can be routed, rear or right side of unit when facing front. Ceiling mounted can be routed straight downward. 5. Pull air filters upward (Figure 6). Note: = A 0.49" x 1.575" - 4 SLOT (Mounting hole) (12.5 mm 40.0 mm) Unit Size MCX 512-518 MCX 524 MCX 530-536 MCX 042-048 MCX 060 B 36.2" (920) 46.1" (1,170) 55.9" (1,420) 65.7" (1,670) 75.6" (1,920) 8. Place or hang the unit at the selected position. 9. Replace both right and left side panels, and the return grille after the installation of wiring, tubing and piping is complete. Figure 8 Outdoor Unit See the proper installation method provided in the Installation Manual for the outdoor unit. Pull Pull Figure 9 Figure 6 6 MS-SVN015-EN MS-SVN015-EN.p65 6 Black 6/27/07, 11:23 AM Connection of Refrigerant Tubing The indoor unit refrigerant line connections are flared both 50 Hz and 60 Hz. Installation brazing, leak testing, and evacuation of refrigerant lines are covered in the Installer Manual, packaged with the outdoor unit. Read the instructions before installing the refrigerant lines. When reaming, hold the tube end downward and be sure that no copper scraps fall into the tube. 3. Remove the flare nut from the unit and be sure to mount it on the copper tube. After Figure 13 4. Make a flare at the end of copper tube with a flare tool (Figure 14, 15). Flare nut Figure 11 5. When bending the tube, be careful not to crush it. To prevent crushing of the tube, bend it gently and do not bend the tube at a radius curvature of less than 100 mm. 6. If the copper tube is bent or pulled too often, it will become stiff. Do not bend the pipe more than three times at one place. Cautions before connecting tubes tightly Connecting the unit with flaring procedure. (Only for MCX 512-536) Copper tubing Flare tool Figure 14 7. Be sure to apply a sealing cap or water-proof tape to prevent dust or water from getting into the tubes before they are used. 8. Be sure to apply refrigerant lubricant to the matching surfaces of the flare and union before connecting them together. This is effective for reducing gas leaks (Figure 16). L 2. Hold each pipe downward when cutting and remove burrs at the end of the copper tube with a tube reamer or file. This process is important and should be done carefully to make a good flare (Figure 12 and Figure 13). Check if (L) is flared uniform and is not cracked or scratched. L Dimension: 1.4 to 1.7 mm (6.35 mm dia) 1.8 to 2.0 mm (9.53 mm dia) 1.9 to 2.2 mm (12.7 mm dia) 2.1 to 2.4 mm (15.88 mm dia) Reamer Inside surface is glossy and smooth. Edge is smooth. Tapered sides are of uniform length. Bending Before Copper tubing - Deburring The indoor unit refrigerant piping connections are located on the right hand side when facing the unit (Figure 11). 1. Flaring (If piping is procured or cut at the site). Cut the copper tube to the required length with a tube cutter. It is recommended to cut approx. 30-50 cm. longer than the tubing length you estimate. A good flare should have the following characteristics: Apply refrigerant lubricant here Figure 16 Figure 12 Figure 15 MS-SVN015-EN 7 MS-SVN015-EN.p65 7 Black 6/27/07, 11:23 AM Connection of Refrigerant Tubing Connection Connecting the unit with brazing procedure (Only for MCX 042-060) 9. For proper connection, align the union tube and flare tube straight with each other, then screw in the flare nut lightly at first to obtain a smooth match (Figure 17). Union 1. Cut the copper tube to the required length with a tube cutter. It is recommended to cut approx. 20-30 cm. longer than the tube length you estimate. 2. Remove burrs at the end of the copper tube with a tube reamer (Figure 12). 3. There are 2 ways to connect the copper tube - Use a coupling between the copper tube of indoor unit and the copper tube used for installation (Figure 19). Flare nut Figure 17 10. Tighten the flare nut to the specified tightening torque with torque wrench and adjustable wrench (Figure 18). Torch Copper tube of indoor unit Solder coupling Flare Nut Tightening Torque Flare Nut/Piping Size Tightening kgf, - cm 5. Insulate the entire gas line. 6. Do not allow uninsulated liquid line to come in direct contact with bare gas line. 7. Precautions should be taken to avoid heat damage to the pressure tap valve core during brazing. It is recommended that a wet rag be wrapped around the valve body. 8. It is recommended to use braze shield, soak pad in water and place over suction and liquid lines to protect unit finish. 9. To braze the copper tube, before brazing a copper tube to a solder coupling or a copper tube to an expanded tube, do not forget to keep them tight as shown in Figure 21, 22. CO MM ET Copper tube from indoor unit 3 Solder rod Solder coupling Torque lbf-in Copper tube from outdoor unit Copper tube of outdoor unit 6.35 mm (1/4") dia. 150~200 130~170 9.53 mm (3/8") dia. 350~400 300~340 Figure 21 Figure 19 12.7 mm (1/2") dia. 500~550 430~470 - Expand the copper tube by using a swaging tool set as in Figure 20. 15.88 mm (5/8") dia. 600~650 520~570 Swaging tool Torch CO MM ET Copper tube from indoor unit 3 Solder rod Solder coupling Copper tube from outdoor unit Wrench (adjustable) Indoor unit pipe Torque wrench Tube holder (Clamp) Copper tube Connection pipe Flare nut Figure 18 Figure 20 11. Repeat the process above for the remaining line. 4. Clean internal and external surfaces of coupling or expanded tube prior to brazing. 8 Figure 22 10. Use a dry nitrogen purge and brazing alloy without flux when brazing the field line to the copper factory connection. Flow dry nitrogen into either valve pressure tap port, through the tubing and out the other port while brazing. 11. Braze using accepted good brazing techniques. MS-SVN015-EN MS-SVN015-EN.p65 8 Black 6/27/07, 11:23 AM Condensate Drain Piping - The drain hose should run straight down the wall to a level where the runoff will not stain the wall. - There should be no traps. Avoid putting the end of the hose in water. - To conveniently drain the system, the drain hose must slant downward, with a slope of at least 1 : 50 to prevent leakage. Figure 23 shows the unit in the floor mounted position. - When the drain hose is placed in the room, insulate the hose with foam polyethylene to avoid damage to the ceiling or furniture. - After completing installation of refrigerant lines, wiring and drain connections, bind the tubing, wiring and drain hose (check if local codes permit binding) into a bundle by using tape at 100 or 200 mm (4" to 8") intervals. Make sure the drain hose is at the bottom of the bundle (Figure 24). Indoor unit Slant Drain hose Figure 24 Drain hose Figure 23 MS-SVN015-EN 9 MS-SVN015-EN.p65 9 Black 6/27/07, 11:24 AM Electrical Installation All wiring and grounding must comply with local electrical codes. 1. Wiring Important Safeguards: - Check the unit nameplate for electrical rating. Be sure wiring is done according to local codes and wiring diagram. - Use a separate power line with circuit breaker for each air conditioning unit. - Connect electrical ground to all units. - Wiring should not touch refrigerant tubing, compressor, motors or moving parts. - The manufacturer will accept no responsibility for problems caused by unauthorized changes in the internal wiring. - Connect the wiring firmly. 2. Electrical Connections See Section: Wiring System Diagram Indoor Unit Remove the right side panel and return grille (see previous instructions), to access the terminal base. - Pass the system wiring through the PVC pipe (both power and control lines) to interconnect indoor and outdoor units. - Connect the wire terminals to the terminal base (see connection indication on system wiring diagram). - Make sure all connections are tight. Outdoor unit Outdoor Unit - Indoor Unit Electrical Interconnection should be in accordance with the applicable system wiring diagram and indoor unit diagrams. Outdoor unit diagram are contained in the outdoor unit Installer Manual. Note: - 10 All wiring must comply with national state and local codes. After completing the connections, re-confirm them to be in accordance with the unit and system wiring diagrams. MS-SVN015-EN MS-SVN015-EN.p65 10 Black 6/27/07, 11:24 AM Remote Control Installation Locate and attach the wireless remote control and wired control as follows: 1. Do not place the control and the remote control near heat sources or expose to the direct rays of the sun. 2. Do not expose the control to the indoor unit’s supply air stream. 3. Do not place in a confined space. 4. Attach the remote control holder as shown in Figure 25, 26. 90.0 61.0 14.5 90.0 45.0 14.5 ECON 45.0 4.0 X 2 SLOT O FAN ON COOL DRY OFF HEAT POWE AUTO RCOO L Z SW Dimension Z MO DE LO ON UVE R SW EE P FR BLAONT DE POW ER COOL OFF ECON O SLEE P LIG HT SEND ON SW SL OF AU TO F EC EE ON P O EC TU O RB ON NO O TU OF RB F O TE MP ME NU MO DE FA N Wireless Remote Control Remote Control Figure 25 Mounting Bracket Figure 26 MS-SVN015-EN 11 MS-SVN015-EN.p65 11 Black 6/27/07, 11:24 AM Typical Wiring Diagram MCX512-536GB (50 Hz) MCX512-536G1 (60 Hz) INDOOR UNIT, COOLING ONLY WITH CONTROL TYPE “R”, 4 SPEED 1. FREEZE SENSOR LOCATED ON EVAPORATOR COIL 2. TEMPERATURE SENSOR LOCATED IN RETURN AIR STREAM 1 2 GRN/YL ROOM STEPPER TOP P22 P21 FREEZE P26 DISPLAY P20 SWEEP MOTOR (OPTION) P17 P16 P7 J2 J1 BLK MED LOW P6 YL RED HI P5 BLU RED LINE-C EX-HI P4 BLK LINE P3 RED NEUTRAL P1 P2 WHT RED P19 STEPPER FRONT INFRARED RECEIVER YL BLU N C1 C2 BLK L WHT WIRELESS REMOTE CONTROLLER RED WHT GRN/YL WIRING TO GROUNDING SYSTEM BRW POWER SUPPLY 220-240VAC/1PH/50Hz 220-240VAC/1PH/60Hz BLOWER MOTOR 200-240 VAC CONTROL WIRING TO OUTDOOR UNIT DESCRIPTION COLOR CODE FIELD WIRING FACTORY WIRING COIL JUNCTION TERMINAL BOARD BLU BLK RED WHT GRN YL BR BLUE BLACK RED WHITE GREEN YELLOW BROWN CAPACITOR FUSE 3 AMP. 12 MS-SVN015-EN MS-SVN015-EN.p65 12 Black 6/27/07, 11:24 AM Typical Wiring Diagram MCX042-060GB (50 Hz) MCX042-060G1 (60 Hz) INDOOR UNIT, COOLING ONLY WITH CONTROL TYPE “R”, 3 SPEED 1. FREEZE SENSOR LOCATED ON EVAPORATOR COIL 2. TEMPERATURE SENSOR LOCATED IN RETURN AIR STREAM 1 2 GRN/YL P16 P6 J2 J1 BLK RED MED LOW P5 BLU RED LINE-C HI P4 BLK LINE P3 RED NEUTRAL P1 P2 WHT RED INFRARED RECEIVER ROOM P17 P22 P21 FREEZE P26 DISPLAY BLK N C1 C2 BLU L WHT WIRELESS REMOTE CONTROLLER RED WHT GRN/YL WIRING TO GROUNDING SYSTEM BRW POWER SUPPLY 220-240VAC/1PH/50Hz 220-240VAC/1PH/60Hz BLOWER MOTOR 200-240 VAC CONTROL WIRING TO OUTDOOR UNIT DESCRIPTION COLOR CODE FIELD WIRING FACTORY WIRING COIL JUNCTION TERMINAL BOARD BLU BLK RED WHT GRN YL BR BLUE BLACK RED WHITE GREEN YELLOW BROWN CAPACITOR FUSE 3 AMP. MS-SVN015-EN 13 MS-SVN015-EN.p65 13 Black 6/27/07, 11:24 AM Typical Wiring Diagram MCX512-536GB (50 Hz) MCX512-536G1 (60 Hz) INDOOR UNIT, COOLING ONLY WITH CONTROL TYPE “W”, 4 SPEED 1. FREEZE SENSOR LOCATED ON EVAPORATOR COIL 2. TEMPERATURE SENSOR LOCATED IN RETURN AIR STREAM 1 2 GRN/YL P21 FREEZE DISPLAY ROOM STEPPER TOP P22 P31 P20 SWEEP MOTOR (OPTION) P17 P16 P7 J2 J1 BLK MED LOW P6 YL RED HI P5 BLU RED LINE-C EX-HI P4 BLK LINE P3 RED NEUTRAL P1 P2 WHT RED P19 STEPPER FRONT WIRE DISPLAY YL BLU BLK N C1 C2 WHT L RED WHT GRN/YL WIRING TO GROUNDING SYSTEM BRW POWER SUPPLY 220-240VAC/1PH/50Hz 220-240VAC/1PH/60Hz BLOWER MOTOR 200-240 VAC CONTROL WIRING TO OUTDOOR UNIT DESCRIPTION COLOR CODE FIELD WIRING FACTORY WIRING COIL JUNCTION TERMINAL BOARD BLU BLK RED WHT GRN YL BR BLUE BLACK RED WHITE GREEN YELLOW BROWN CAPACITOR FUSE 3 AMP. 14 MS-SVN015-EN MS-SVN015-EN.p65 14 Black 6/27/07, 11:24 AM Typical Wiring Diagram MCX042-060GB (50 Hz) MCX042-060G1 (60 Hz) INDOOR UNIT, COOLING ONLY WITH CONTROL TYPE “W”, 3 SPEED 1. FREEZE SENSOR LOCATED ON EVAPORATOR COIL 2. TEMPERATURE SENSOR LOCATED IN RETURN AIR STREAM 1 2 GRN/YL P21 P31 P16 LOW P6 RED J2 J1 BLK MED P5 BLU RED LINE-C HI P4 BLK LINE P3 RED NEUTRAL P1 P2 WHT RED WIRE DISPLAY ROOM P17 P22 FREEZE DISPLAY GRN/YL BLU WHT BLK N C1 C2 RED L WHT WIRING TO GROUNDING SYSTEM BRW POWER SUPPLY 220-240VAC/1PH/50Hz 220-240VAC/1PH/60Hz BLOWER MOTOR 200-240 VAC CONTROL WIRING TO OUTDOOR UNIT DESCRIPTION COLOR CODE FIELD WIRING FACTORY WIRING COIL JUNCTION TERMINAL BOARD BLU BLK RED WHT GRN YL BR BLUE BLACK RED WHITE GREEN YELLOW BROWN CAPACITOR FUSE 3 AMP. MS-SVN015-EN 15 MS-SVN015-EN.p65 15 Black 6/27/07, 11:24 AM Dimensional Data OUTLINE DIMENSIONS MCX512-536GB (EXPORT 50 Hz) MCX512-536G1 (EXPORT 60 Hz) DIMENSIONAL DATA CONN. SIZES A TYPE B C MODEL LIQUID SUCTION CONNECTIONS. MCX512GB/G1 MCX518GB/G1 1/4 (6.4) 1/2 (12.7) FLARED 42.28 (1074.0) MCX524GB/G1 3/8 (9.5) 5/8 (15.9) FLARED 51.13 MCX530GB/G1 3/8 (9.5) 5/8 (15.9) FLARED MCX536GB/G1 3/8 (9.5) 3/4 (19.0) FLARED NOTE IN. (MM.) IN. (MM.) EACH 34.61 (879.0) 4 (1324.0) 44.45 (1129.0) 4 61.97 (1574.0) 54.29 (1379.0) 6 61.97 (1574.0) 54.29 (1379.0) 6 1) SUCTION AND LIQUID LINES HAVE FLARE TYPE CONNECTIONS. 2) DIMENSIONS : MILIMETERS [INCHES] 25.4 MM. = 1 IN. 16 MS-SVN015-EN MS-SVN015-EN.p65 16 Black 6/27/07, 11:24 AM Dimensional Data OUTLINE DIMENSIONS MCX042-060GB (EXPORT 50 Hz) MCX042-060G1 (EXPORT 60 Hz) DIMENSIONAL DATA CONN. SIZES TYPE A B C D MODEL LIQUID SUCTION CONNECTIONS. MCX042GB/G1 MCX048GB/G1 3/8 (9.5) 3/8 (9.5) 7/8 (22.2) 1-1/8 (28.6) BRAZED BRAZED 71.81 (1824.0) 64.13 (1629.0) 8 15.76 (400) MCX060GB/G1 3/8 (9.5) 1-1/8 (28.6) BRAZED 81.65 (2074.0) 73.98 (1879.0) 8 23.64 (600) NOTE IN. (MM.) 1) DIMENSIONS : MILIMETERS [INCHES] IN. (MM.) EACH IN. (MM.) 25.4 MM. = 1 IN. MS-SVN015-EN 17 MS-SVN015-EN.p65 17 Black 6/27/07, 11:24 AM Notes 18 MS-SVN015-EN MS-SVN015-EN.p65 18 Black 6/27/07, 11:24 AM Notes MS-SVN015-EN 19 MS-SVN015-EN.p65 19 Black 6/27/07, 11:24 AM Trane A business of American Standard Companies www.trane.com For more information, contact your local district office MS-SVN015-EN.p65 Literature Order Number: MS-SVN015-EN Date: Jul 2007 Supersedes: Oct 2002 Stocking Location: Bangkok, Thailand Trane has a policy of continuous product and product data improvement and reserves the right to change design and specific ations without notice. Only qualified technicians should perform the installation and servicing of equipment referred to in this publication. 20 Black 7/18/07, 11:06 AM